BRPI0507362B1 - HYDROCARBON ALCHILATION USING A NANOCRISTALINE ZEOLIT CATALYST - Google Patents

Description

"HYDROCARBON ALCHILATION USING A NANOCRISTALINE ZEOLIT CATALYST" CROSS-REFERENCE TO RELATED APPLICATIONS This patent application relates in part to US 10 / 067,719 filed February 5, 2002, which is here incorporated by reference, and for which priority is claimed.

BACKGROUND 1. Field of the Invention The present invention relates to a method for converting hydrocarbon compounds, and particularly to the use of a zeolite catalyst for olefin / paraffin alkylation or aromatic alkylation. 2, Background of the Art Alkylation pertains to the chemical addition of an alkyl group to another molecule to form a larger molecule.

Commercial alkylation processes may typically be aromatic alkylation or olefin / paraffin alkylation. Aromatic alkylation typically involves the production of alkylaromatic compounds (eg ethylbenzene, cumene, etc.) by alkylation of an aromatic compound (eg benzene) with an olefin (eg ethylene, propylene, etc.). ). Olefin / paraffin alkylation belongs to the reaction between an olefin-saturated hydrocarbon to produce a highly branched, saturated hydrocarbon, for example, alkylation of isobutane with 2-butene to produce a gasoline product having a high number of octane.

Unlike gasoline production by cracking high molecular weight oil fractions such as diesel fuel or petroleum residue, alkylation yields a cleaner gasoline product without sulfur or nitrogen impurities. In addition, alkylated gasoline has little or no aromatic content, which is an additional environmental benefit. Various alkylation processes are known and used throughout the petroleum industry. For example, alkylation is routine and commercially effected by the use of liquid acid catalysts such as sulfuric acid or hydrofluoric acid. Alternatively, solid zeolite catalysts have been used. Use of zeolites avoids the disadvantages of using highly corrosive liquid toxic acids. However, zeolites may undergo deactivation caused by coking. Various processes for alkylating hydrocarbons using zeolite-containing catalysts are described in US Patent 3,549,557 and US Patent 3,815,004. An alkylation process using a solid acid catalyst employing a zeolitic or non-zeolitic material is shown in US Patent 5,986,158, which is incorporated herein by reference.

Zeolites are porous crystalline materials characterized by submicroscopic channels of a particular size and / or configuration. Zeolites are typically composed of aluminosilicate, but zeolite materials have been made in a wide variety of other compositions. The latter are commonly referred to as microporous materials. The channels, or pores, are ordered and as such provide unique properties that make zeolites useful as catalysts or absorbers in industrial processes. For example, zeolites can be used to filter smaller molecules that get trapped in the pores of the zeolite. Also, zeolites can function as selective catalysts in ways that favor certain chemical conversions within the pores according to the shape or size of molecular reagents or products. Zeolites are also useful in ion exchange, such as for water softening and selective recovery of heavy metals.

Synthetic zeolites are traditionally made from silica and aluminum sources (silica and alumina "nutrients") that react with each other in the presence of materials that ensure highly alkaline conditions such as water and OH '. Other zeolites may be borosilicates, ferrosilicates, and the like. Many of the crystallization steps are conducted in the presence of an organic directing agent, or an organic pattern, which induces a specific zeolite structure that cannot easily be formed in the absence of the directing agent or pattern. Many of the organic standards are quaternary ammonium salts, but may also be linear amines, alcohols, and a variety of other compounds. Like a hydroxide, some directing agents introduce hydroxyl ions into the reaction system; However, alkalinity is usually dictated by the amount of sodium hydroxide (NaOH), potassium hydroxide (KOH), etc. The reaction typically involves a liquid gel phase in which rearrangements and transitions occur, such that a redistribution occurs between the alumina and silica nutrients, and molecular structures are formed that correspond to specific zeolites. Other metal oxides may also be included such as titania silica, boria silica, etc. Some zeolites can only be made with organic standards. Other zeolites can be made only by an inorganic targeting agent. Still other zeolites may be made either by a hydrophilic (e.g. inorganic) targeting agent or by a hydrophobic (organic-based) pattern.

Much of today's hydrocarbon processing technology is based on zeolite catalysts. Various zeolite catalysts are known in the art and have well-arranged pore systems with uniform pore sizes. The term "middle pore" as applied to zeolites usually refers to zeolite structures having a pore size of 4 to 6 angstrons (Å). "Large pore" zeolites include structures having a pore size of from about 6 to about -12 Å. Since many industrially relevant (ie, high) conversion rates of hydrocarbon processing reactions are limited by mass transfer (specifically, intra-particle diffusion), a catalyst particle with an ideal pore structure will facilitate transporting reagents to active catalyst sites within the particle and transporting products outside the catalyst particle, but still achieving selective catalysis in a desired manner. Zeolite morphology, ie crystal size, is another parameter in diffusion-limited reactions.

Catalysts have a limited life, for example due to coking. Catalyst deactivation usually requires reactor shutdown and catalyst regeneration. Although the use of two reactors operated in a "reciprocating mode" (ie alternate use of reactors where one is operated for alkylation while the other is stopped for regeneration) allows continuous production, it is nevertheless preferable to perform reactive reactions. alkylation with zeolite catalysts that have a long life to minimize economic losses incurred by reactor shutdown and catalyst regeneration.

SUMMARY A process for alkylating a hydrocarbon compound is provided herein. The process comprises providing a catalyst including a zeolite Y having a crystal size of no more than 100 nm; and reacting the hydrocarbon capable of being alkylated with an alkylating agent in the presence of said catalyst under alkylation reaction conditions to provide an alkylated product. The process described herein advantageously provides a high octane Research ("RON") alkylated product as well as an alkylation reaction having a longer operating time. DETAILED DESCRIPTION OF PREFERRED EMBODIMENT (S) The alkylation method described herein employs an ultra-small, or nanocristine crystal size zeolite, that is, a crystal size of no more than about 100 nanometers (" nm "). Nanocrystalline zeolite has several advantages over certain hydrocarbon conversion processes. For example, the effective diffusibility of many reagents and products is increased.

Second, product selectivity is increased by certain processes, especially sequential reactions, where an intermediate product is desired. For example, ultra-small crystal size may reduce the amount of (1) super cracking (for example, the production of C3 / C4 light gas cracking gas products in which the distillate and naphtha products are the desired products) and (2) unwanted polyalkylation in aromatic alkylation process. Also, coking, and associated catalyst deactivation, is reduced to nocrystalline zeolites by allowing coke precursors to leave the catalyst before undergoing backward condensation reactions.

Third, nanocrystalline zeolite catalyst activity is higher for larger zeolite crystal catalysts, as diffusion limitation limits the accessibility of internal active sites in the latter case, resulting in a greater effective number of active sites by weight. from catalyst to nanocrystalline zeolite catalyst. The method of the invention is described below in connection primarily with the use of zeolite Y as produced by the method described in commonly owned co-pending patent application US 10 / 067,719 for alkylation catalysis. Nanocrystalline Y Zeolite produced according to the application method 10 / 067,719 has a cubic faujasite structure with an effective pore diameter of about 7 to 8 Å and a unit cell size of less than 25 Å. Zeolite Y as synthesized also preferably has a molar silica to alumina ratio of less than about 10, often less than about 7. The crystal size of nanocrystalline Y zeolite is no more than about 100. nm, preferably no more than about 50 nm, and more preferably no more than about 25 nm.

Although nanocrystalline Y zeolite synthesis can be performed in the presence of an organic standard, the preferred mode in terms of catalyst production costs is the use of inorganic directing agents.

Nanocrystalline Y Zeolite is useful for various hydrocarbon conversion processes, such as: alkylation and transalkylation of aromatics in ethylbenzene or cumene production, paraffin alkylation with olefins for high octane gasoline production, vacuum gas oil hydrocracking produce transport fuels, hydro-processing to make lubricant oil base stocks, preparation of alkylbenzenes or straight alkylnaphthalenes, selective hydrogenation, aromatic nitration, etc. The method for preparing nanocrystalline Y zeolite includes impregnating a porous, solid, silica-alumina particle or structure with a concentrated aqueous solution of an inorganic micropore forming targeting agent by incipient wet impregnation. The porous silica-alumina material may be amorphous or crystalline. The amount of liquid is less than the amount of liquid that would cause surface gel formation visible to the naked eye. The liquid supplied to the solid porous silica-alumina particle or structure is absorbed and moistens the inner voids of the latter, but does not form a paste-like material therewith. The liquid includes water, inorganic micropore forming targeting agent and also, if necessary, an organic standard. The organic standard is selected according to desired product. Typical organic standards useful in zeolite synthesis include quaternary ammonium salts, linear amines and diamines, and alcohols. More specifically, particular organic standards include tetramethyl ammonium hydroxide or salts thereof, tetraethyl ammonium hydroxide or salts thereof, tetrapropyl ammonium hydroxide or salts thereof, pyrrolidine, hexane-1,6-diamine, hexane-1 , 6-diol, piperazine, and 18-crown-6 ethers. The normanic microporous forming targeting agent provides hydroxide ions and may be an alkali metal base or an alkaline earth metal base. However, with respect to the preparation of zeolite Y of the present invention, preferred microporous forming targeting agents are inorganic alkali metal hydroxides, and preferably sodium hydroxide (NaOH). Organic patterns are not used. Since high pH favors the formation of zeolite Y over other crystalline phases, as well as rapid nucleation and crystallization, high concentrations of caustic directing agent are required. For example, when using a concentration of 20% (by weight) or less of NaOH, other crystal phases such as cancrinite or zeolite P can be formed, no conversion can occur, very large Y zeolite crystals can be formed. formed, or conversion may take an unacceptably long period of time.

It has been surprisingly found that higher concentrations of inorganic targeting agent significantly reduce the required reaction time. A preferred concentration range of NaOH in aqueous solution is from 21% to about 60% by weight, more preferably it is from 25% to about 60% by weight NaOH. Most preferred is a 45 to 50% by weight NaOH concentration. Since higher NaOH concentrations result in excessively high viscosity and incomplete internal wetting, the intermediate concentration range represents an optimal level.

To maintain a "dry" material, the amount of inorganic targeting agent solution should not exceed 100% of the pore volume of the pore inorganic oxide material, and preferably ranges from about 8% to about 100% of the pore content. pore volume. The degree of uniformity of the impregnation is important for the success of crystallization of zeolite Y. Localized non-uniformity may result in formation of non-zeolite Y byproduct. To provide mixing on a small scale (eg in the range (from several grams to 100 grams) a grain can be used to mix the silica alumina with the microporous forming targeting agent solution. On a larger scale, a mixer in combination with a sprayer may be used. The combined porous silica / amorphous silica / targeting agent (NaOH) synthesis mixture is then placed in a heating medium and heated to a high temperature of about 50 ° C to about 150 ° C, plus preferably from about 70 ° C to about 110 ° C. Uniform heating of the synthesis mixture is desired to prevent the formation of large zeolite crystals. The synthesis mixture is maintained at synthesis temperature for a period of time sufficient to convert a sufficient amount of the silica alumina to zeolite Y. The final frame structure after crystallization contains a substantial crystalline content (by weight), typically at least 15%. %, preferably at least 50% and more preferably from about 75% to about 100% zeolite. The synthesis time period may depend on the synthesis temperature, lower synthesis temperatures require longer synthesis times. Synthesis time may range from 5 minutes to 150 hours, although more typically from 10 minutes to 48 hours, and preferably from about 15 minutes to about 30 hours.

After the required synthesis time, the synthesis mixture is preferably quenched by active cooling. Subsequently, the microporous forming targeting agent should be removed from the product to prevent further reaction at subsequent treatment steps or during storage. Then sodium should be removed from the zeolite frame, for example by ammonium exchange, using ion exchange techniques well known to those skilled in the art.

Optionally, the zeolite may be mixed with a matrix material, binder, or catalyst support material.

Such materials include silica, alumina, aluminosilic, thymania, zirconia and the like. Preferably, the catalyst of the invention includes nanocrystalline Y zeolite and about 5% to 40% by weight of refractory oxide binder such as alumina, silica, silica alumina, titania, zirconia, etc. The ion-exchanged zeolite has a sodium content of no more than about 0.2%, more preferably no more than about 0.1% by weight, and even more preferably no more than about 0.05%. % by weight.

Nanocrystalline Y Zeolite produced according to the method of the invention has a mesopore to micropore volume ratio of about 0.2 to about 6.0, a BET surface area of at least about 275 m2 / g and a unit cell size from about 24.6 Ã… to about 24.9 Ã….

Optionally, a catalytically active metal may be incorporated into the zeolite by, for example, ion exchange or zeolite impregnation, or by incorporation of the active metal into the synthesis materials from which the zeolite is prepared. The metal may be in a metal form or in combination with oxygen (eg metal oxide). Suitable catalytically active metals depend on the particular process in which the catalyst is intended to be used and generally include, but are not limited to, Group VIII metals (e.g., Pt, Pd, Ir, Ru, Rh, Os, Fe, Co, Ni), rare earth "lanthanide" metals (eg La, Ce, Pr, etc.), Group IVB metals (eg Ti, Zr, Hf), Group metals VB (eg V, Nb, Ta), Group VIB metals (eg Cr, Mo, W), or Group IB metals (eg Cu, Ag, Au). In a preferred embodiment, the catalytic metal is a rare earth metal, preferably lanthanum, or a rare earth metal mixture having a high lanthanum content, with a rare earth metal to zeolite mass ratio. of at least about 0.04, preferably at least about 0.08. Another catalytic metal is a noble metal, preferably platinum, with a zeolite metal mass ratio of at least about 0.0001, preferably at least about 0.001.

In one embodiment, the method of the present invention employs a nanocrystalline Y zeolite as a catalyst for olefin / paraffin alkylation. It has been surprisingly found that the use of nanocrystalline Y zeolite having a crystal size of no more than 100 nm, preferably no more than 50 nm, and more preferably no more than 25 nm, results in longer catalyst life than Zeolite Y

conventional, and the resulting gasoline product has a higher RON, typically at least about 99.5. The catalyst of the invention is particularly suitable for alkylation of isoalkanes having from 4 to 10 carbon atoms, such as isobutane, isopentane or isoexane or mixtures thereof, with olefins having from 2 to 10 carbon atoms, preferably 2 to 6 carbon atoms, more preferably 3 to 5 carbon atoms. Alkylation of isobutane with butene or a mixture of butenes is an attractive embodiment of the process according to the invention.

In another embodiment, the catalyst of the invention may be used for alkylation of an aromatic compound, such as benzene, with an olefin (e.g., ethylene, propylene, 1-butene, 2-butene, isobutene, etc.) to produce zir a corresponding alkylaromatic compound (eg ethylbenzene, cumene, diisopropylbenzene, etc.). Also, the catalyst may be used for the transalkylation of polyalkylated aromatics with empty ring aromatics (e.g. benzene) to provide monoalkylated aromatics.

As will be apparent to one skilled in the art, the process according to the invention may be applied in any suitable form, including fluid bed processes, mud processes and fixed bed processes. The process may be carried out in several beds, each with a separate addition of olefin. In such a case, the process of the invention may each be carried out in a separate bed. The olefin paraffin alkylation process is carried out under conditions such that at least a portion of the alkylating agent and the alkylatable compound will be in the liquid or supercritical phase. In general, the process according to the invention is conducted at a temperature in the range of about -40 ° C to about 250 ° C, preferably in the range of about 50 ° C to about 150 ° C. C, more preferably in the range from about 75 ° C to about 95 ° C, and a pressure of about 100 kPa to 10,000 kPa (1 to 100 bar), preferably from about 1000 kPa to 4,000 kPa (10 to 40 bar), more preferably from 1,500 kPa to 3,000 kPa (15 to 30 bar). The molar ratio of compound capable of being alkylated to alkylating agent in the total feedstock in the reactor is preferably greater than 5: 1, more preferably greater than 50: 1. The feed rate (WHSV) of the alkylating agent is generally in the range 0.01 to 5, preferably in the range 0.05 to 0.5, more preferably in the range 0.1 to 0.4 part. of alkylating agent per catalyst part per hour. The WHSV of the saturated hydrocarbon capable of being alkylated is preferably in the range 0.1 to 500 h -1.

Another preferred process is aromatic alkylation such as alkylation of benzene with ethylene to produce ethylbenzene or alkylation of benzene with propylene to produce cumene, which may be carried out in a batch, in semi-continuous or continuous mode.

The examples below illustrate various features of the process of the present invention. Comparative examples do not exemplify the invention, but are provided for the purpose of showing, by comparison, the surprising improvements obtained by the present invention with respect to the use of conventional Y-zeolite catalyst for olefin / paraffin alkylation, particularly for alkylation of isobutane with cis-2-butene to produce gasoline products. In all examples, olefin and paraffin were fed into a fixed bed reactor immersed in an oil bath to maintain a desired temperature. The reactor effluent was divided into two portions. A portion of the product was cycled back to the reactor as a recycling stream into which the olefin / paraffin feed was injected.

Another portion, a product recovery stream, was sent to a condenser for separation of the alkylated product. Reactor effluent samples were taken for testing prior to separation of the product stream into a recycling stream and product recovery stream.

A test was performed to determine the catalyst operating life by observing the operating time that elapses before the "olefin break", that is, the point at which 0.2% olefin leaves the reactor unconverted. - had. Reactor effluent was monitored by chromatographic analysis to determine when olefin peaks appeared. Catalyst life is an important feature since the better the catalyst longevity, the less need to remove the catalyst from line for regeneration.

Also, the total RON of the product was monitored. Each component of the product stream is characterized by a respective RON. Preferred alkylation products are trimethylpentanes ("TMP"), which have high octane research numbers (RON from about 100 to 110). The total RON of the alkylated product, which represents the anti-knock quality of gasoline, was determined by calculating the weighted average of the RON values of the individual product components. COMPARATIVE EXAMPLE 1 The zeolite catalyst evaluated in this Comparative Example was a commercially available HY zeolite containing 70% by weight of HY zeolite in an alumina binder. The crystal size of the zeolite in this sample was 0.4-0.7 microns (i.e. 400-700 nm). The zeolite catalyst was derived from 0.774 mm (1/32 inch) and -18 to +25 mesh extrudates with a BET surface area of 562 m2 / g. The test reactor was a recirculating differential fixed bed reactor in a system as described above with feed containing isobutane and cis-2-butene at an isobutane / olefin (1/0) ratio of 15.9 with a feed rate of 16.2 parts / h. 4.6 Parts by weight of zeolite catalyst were loaded into the reactor. The catalyst was pretreated under nitrogen flow at 300 ° C for 2 hours to remove moisture before the alkylation test began.

Alkylation was conducted at 2.758 MPa (400 psig) and 80 ° C with a recycle rate of 174 parts of reaction effluent per parts of catalyst per hour. The test was performed with samples taken every 45 minutes for gas chromatography analysis until olefin disruption. The catalyst life, as determined by olefin disruption, for this commercial zeolite Y catalyst was 2.7 hours. The RON as measured before olefin rupture was calculated to be 99.1. These results are summarized in Table 1. COMPARATIVE EXAMPLE 2 The zeolite catalyst using in this Comparative Example was 3.6 parts of commercially available HY zeolite derived from 1.588 mm (1/16 inch) extrudates. ) containing 80% by weight of zeolite HY in an alumina binder. The zeolite crystal size of this sample was 0.4-0.7 microns. The dried catalyst was sieved to -18 to +25 mesh with a BET surface area of 556 m2 / g. The pretreatment and alkylation reaction and conditions were conducted in the same manner as in Comparative Example 1. The results are set forth in Table 1. COMPARATIVE EXAMPLE 3 The zeolite catalyst used in this Comparative Example was 3, 6 parts by weight of a commercially available HY zeolite derived from 1.588 mm (1/16 inch) extrudate containing 80% by weight of HY zeolite in an alumina binder. The zeolite crystal size of this sample was 0.4-0.7 microns. The dried catalyst was sieved to -18 to +25 mesh with a BET surface area of 564 m2 / g. Pretreatment and alkylation reaction and conditions were conducted in the same manner as in Comparative Example 1.

Example 1 This example illustrates the invention. A part of porous silica-alumina with a silica / alumina ratio ("SAR") of 5.1 was impregnated with 1.05 part of a solution containing 45 parts by weight of NaOH and 55 parts of distilled water. The impregnated material after aging was placed in an autoclave and heated at 85 ° C for 24 hours. The material was then washed with distilled water and dried at 120 ° C to obtain a product containing> 95% Y zeolite crystals about 25 to 100 nm in size. Nanocrystalline Y zeolite, as synthesized, was ion exchanged with a mixture of LaCl 3 and NH 4 NO 3 solution four times to remove sodium to less than 0.2% by weight. After filtration and washing, the LaNH4Y sample was dried at 120 ° C. The dried powder was then mixed with an appropriate amount of Nyacol alumina sol so that the final calcined product contained a zeolite concentration of about 80 wt%. The paste was dried at 90 ° C for 1 h and then calcined according to the following schedule: 2 ° C / min at 120 ° C maintained for 1 h, 2 ° C / min to 500 ° C, maintained for 2 h, cooling from 5 ° C / min to room temperature.

The calcined pastes were ground and sieved to sizes of + 20 / -12 mesh, of these 4.0 parts in the dry base were loaded into the alkylation reactor for performance evaluation. The BET surface area of the final catalyst was 416 m2 / g. The pretreatment and alkylation reaction conditions were the same as above. This sample had a 6.2 he olylated olefin disruption and had an RON of 100.2 prior to the olefin disruption, as shown in Table 1. EXAMPLE 2 Nanocrystalline Y zeolite, as synthesized above in Example 1, was exchanged. for obtaining LaNH4Y as above. The binding, pretreatment and test conditions were the same as in Example 1. The surface area of this sample was 409 m2 / g. Four parts of the dry catalyst with a particle size of -18 to +25 mesh were charged to the reactor. The sample had a 6.0 olefin rupture and the alkylated product had an RON of 100.3 prior to the olefin rupture as shown in Table 1. EXAMPLE 3 Nanocrystalline Y zeolite as synthesized above in Example 1 was subjected to ion exchange to get LaNH4Y as above. Binding and pretreatment were the same as in Example 1. The surface area of this sample was 389 m2 / g. The alkylation reaction conditions were the same as in Example 1, except that the feed rate was 21.3 parts / h. Four parts of the -18 to +25 mesh dry catalyst were loaded into the reactor. The sample had an olefin rupture of 3.6 h and the alkylated product had an RON of 100.4 prior to olefin rupture as shown in Table 1. EXAMPLE 4 Nanocrystalline Y zeolite as synthesized above in Example 1 was subjected to ion exchange to get LaNH4Y as above. The binding, pretreatment and test conditions were the same as in Example 1. The surface area of this sample was 413 m2 / g. Four parts of the dry catalyst with particle size from -18 to +25 mesh were loaded into the reactor. The sample had an 8.0 hr olefin disruption, and the alkylated product had an RON of 99.5 prior to the olefin disruption as shown in Table 1. EXAMPLE 5 Nanocrystalline Y zeolite as synthesized above in Example 1 was subjected to ion exchange with a solution containing rare earth chloride ("RECI3") and ammonium nitrate (NH4N03) several times to reduce the sodium content to less than 0.2% by weight to obtain REY. The binding, pretreatment and test conditions were the same as in Example 1. The surface area of this sample was 396 m2 / g. 3.6 "parts of the catalyst with particle size from -18 to +25 mesh were loaded into the reactor. The sample had an olefin rupture of 3.4 h and the alkylated product had an RON of 105.5 prior to olefin rupture, TABLE 1 _______________________________________ * After 1 hour of reaction ** After olefin rupture Test results show the unexpected superiority of the nanocrystalline catalyst of the present invention, for example, the average life of the catalyst of Comparative Examples 1 to 3 (conventional Y-zeolite) at an average WHSV of about 0.25 part of olefin per part of the catalyst per hour was 3.9 h with an average RON before olefin breakage of about 98.8 The average catalyst life of Examples 1 to 5 (nanocrystalline Y zeolite) at an average WHSV of about 0.26 part olefin per part catalyst per hour was 5.36 h with a corresponding average RON before. of the olefin rupture of about 100.2.

While the above description contains many specific details, these details should not be construed as limitations on the scope of the invention, but simply as exemplifications of preferred embodiments thereof. Those skilled in the art will consider many other possibilities within the scope and spirit of the invention as defined by the claims appended hereto.

Claims (22)

A process for alkylating a hydrocarbon compound, characterized in that it comprises: a) providing a catalyst including a zeolite Y having a crystal size of no more than 100 nm; b) reacting a hydrocarbon capable of being alkylated with an alkylating agent in the presence of said catalyst under alkylation reaction conditions to provide an alkylated product. Process according to Claim 1, characterized in that the alkylation process is olefin / paraffin alkylation. Process according to Claim 2, characterized in that the hydrocarbon capable of being alkylated is isobutane, and the alkylating agent is a butene. Process according to claim 3, characterized in that the alkylated product comprises a gasoline having an octane research number of at least 99.5. A process according to claim 1, characterized in that the alkylation process is aromatic alkylation. Process according to claim 5, characterized in that the hydrocarbon capable of being alkylated is benzene and the alkylating agent is selected from the group consisting of ethylene, propylene, 1-butene, 2-butene, and isobutene. A process according to claim 1, characterized in that the alkylation process comprises transalkylation, the hydrocarbon capable of being alkylated is an aromatic empty ring compound and the alkylating agent is an aromatic compound. polyalkylated. Process according to Claim 7, characterized in that the empty ring aromatic compound is benzene and the polyalkylated aromatic compound is selected from the group consisting of diethylbenzene and diisopropyl benzene. A process according to claim 1, characterized in that the step of providing a catalyst comprises: a) providing a porous inorganic oxide, b) impregnating the porous inorganic oxide with a liquid solution containing a catalyst. Inorganic microporous formation providing hydroxide ions, wherein the amount of liquid solution is no more than about 100% of the pore volume of the inorganic oxide, and the concentration of the microporous directing agent in the liquid solution varies from about 100%. about 25% to about 60% by weight; and c) heating the impregnated porous inorganic oxide to an elevated synthesis temperature for a period of time sufficient to form a zeolite-containing product. Process according to Claim 9, characterized in that the liquid solution of inorganic microporous targeting agent is an aqueous solution of sodium hydroxide. Process according to Claim 1, characterized in that the zeolite Y has a crystal size of no more than about 50 nm. Process according to claim 1, characterized in that zeolite Y has a crystal size of no more than about 25 nm. Process according to claim 1, characterized in that zeolite Y has a sodium content of no more than about 0.2% by weight. Process according to claim 1, characterized in that zeolite Y has a sodium content of not more than about 0.1% by weight. Process according to claim 1, characterized in that zeolite Y has a sodium content of no more than about 0.05% by weight. Process according to Claim 1, characterized in that the catalyst includes a refractory oxide binder. Process according to Claim 16, characterized in that the refractory oxide binder comprises one or more oxides selected from the group consisting of silica, alumina, silica alumina, titania and zirconia. Process according to claim 1, characterized in that zeolite Y includes one or more metals selected from the group consisting of Pt, Pd, Ir, Ru, Rh, Os, Fe, Co, Ni, La, Ce, Pr, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Cu, Ag and Au. Process according to claim 1, characterized in that zeolite Y includes lanthanum and wherein the lanthanum to zeolite mass ratio is at least about 0.04. Process according to claim 1, characterized in that zeolite Y has a mesopore to micropore volume ratio of from about 0.2 to about 0.6. Process according to claim 1, characterized in that the catalyst has a BET surface area of at least about 275 m2 / g, and wherein zeolite Y has a rare earth metal component with a rare earth metal to zeolite mass ratio of at least about 0.04, wherein the zeolite has a mesopore to micropore volume ratio of about 0.2 to about 6.0, and a unit cell size from about 24.6 Ã… to about 24.9 Ã…. Process according to Claim 1, characterized in that the reaction conditions of the alkylation include a temperature of from about -40 ° C to about 250 ° C, a pressure of about 100 kPa to about 10 Mpa (1 bar to 100 bar), and a WHSV of from about 0.1 to about 500 hr'1.